BYO Guitar JS User manual
Introduction
JS Guitar Intro- 1 -
California requires the following notice:
Warning
These instructions assume that you are familiar with the safe operation and use of woodworking
machinery and woodworking tools, and understand the techniques used to assemble this project. If you do
not qualify for both of these criteria, STOP building this project for your own safety. Read and understand
the owner’s manual for the machinery you intend to use, take a woodworking class or visit your local
library for more information. Woodworking machinery and tools are inherently dangerous because they
use sharp edges that can and will cause serious personal injury including amputation and death. Do not
underestimate the ability of these tools and machinery to cause injury. Never operate any tool without all
guards in place and always wear approved safety glasses. For your own safety, please heed this warning.
Warning
Always wear safety glasses or goggles when operating equipment. Everyday glasses or reading glasses are
not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American
National Standards Institute (ANSI). Because there are various ways to cut and join wood, you can make
substitutions for the methods stated in this manual. We try to suggest the easiest methods possible.
However, only you know your skills with each piece of machinery. Never compromise your safety by using
a cutting method with which you are not comfortable. Instead, find an alternative approach that will yield
the same result.
Warning
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Some examples of these chemicals are:
•Lead from lead-based paints.
•Crystalline silica from bricks, cement, and other masonry products.
•Arsenic and chromium from chemically treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your
exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment,
such as those dust masks that are specially designed to filter out microscopic particles.
Introduction
JS Guitar Intro- 2 -
1Contents
1 Introduction.................................................................................................................................... - 4 -
1.1 Material Check List.................................................................................................................. - 4 -
1.2 Additional tools/materials required:....................................................................................... - 7 -
2 Mockup and Fit Check..................................................................................................................... - 1 -
2.1 Check the Neck Holes in the Body for Size (Fig. 2.1) ............................................................... - 1 -
2.1.1 Enlarge Neck mounting holes in the Body....................................................................... - 1 -
2.2 Check the Mounting Holes in the Neck ................................................................................... - 1 -
2.2.1 Drilling Mounting Holes in the Neck (Fig 2.1) .................................................................. - 1 -
2.2.2 Mount the Neck on the Body .......................................................................................... - 2 -
2.3 The Bridge............................................................................................................................... - 2 -
2.4 Fit check & Alignment of the Pickups (item 11 on material list).............................................. - 2 -
2.5 Check Tremolo Claw Alignment and Fit Check (item #5 on material list)................................ - 3 -
2.6 Fit check of the Covers (Fig 2.6.1) ........................................................................................... - 3 -
2.6.1 Tremolo cover: ................................................................................................................ - 3 -
2.6.2 Audio Cover:.................................................................................................................... - 3 -
2.6.3 Truss Rod Adjustment Access Cover ............................................................................... - 3 -
2.7 Check Strap Pins...................................................................................................................... - 3 -
2.8 Check Tuner Alignment........................................................................................................... - 4 -
2.9 Check Output Jack................................................................................................................... - 4 -
2.10 Check Nut................................................................................................................................ - 4 -
2.11 Mockup and Fit Check complete!............................................................................................ - 4 -
3 Finish............................................................................................................................................... - 1 -
3.1 Finish Application Steps..................................................................................................... - 1 -
3.1.1 Solid Color finish: ........................................................................................................ - 1 -
3.1.2 Pigmented Translucent, Gel stain or alcohol dye finish: ...................................... - 1 -
3.1.3 Penetrating Stain or water based dye finish: ......................................................... - 2 -
3.2 Explanation of Sequence Steps: ........................................................................................ - 2 -
3.2.1 Sanding the Body and Neck ....................................................................................... - 2 -
3.2.2 Appling Grain Filler..................................................................................................... - 2 -
Introduction
JS Guitar Intro- 3 -
3.2.3 Applying Sanding Sealer............................................................................................. - 3 -
3.2.4 Solid Color Primer....................................................................................................... - 3 -
3.2.5 Burst and Translucent finishes................................................................................. - 3 -
3.2.6 Clear Top coats............................................................................................................. - 3 -
3.2.7 Buff finish...................................................................................................................... - 3 -
4 Assembly......................................................................................................................................... - 1 -
4.1 Installing the tuners ................................................................................................................ - 1 -
4.2 Install the Nut ......................................................................................................................... - 1 -
4.3 Neck Installation ..................................................................................................................... - 1 -
4.4 Installing the Strap Pins........................................................................................................... - 1 -
4.5 Installing the Floyd Rose Tremolo (items 4 & 5 on material list)............................................. - 1 -
4.6 Install the Pickup..................................................................................................................... - 2 -
4.7 Prep the for the Output Jack, Volume control & wiring .......................................................... - 2 -
4.7.1 Wire color coding/prep ................................................................................................... - 2 -
4.7.2 Soldering the Components.............................................................................................. - 3 -
4.8 Install the Strings..................................................................................................................... - 4 -
4.9 Tremolo Claw Adjustment....................................................................................................... - 6 -
5 Initial Setup..................................................................................................................................... - 1 -
5.1 Adjust the Guitar Neck: Truss Rod .......................................................................................... - 1 -
5.1.1 Check the Neck................................................................................................................ - 1 -
5.1.2 Adjusting the Truss Rod................................................................................................... - 2 -
5.2 String Lubrication.................................................................................................................... - 2 -
5.3 Re-check the Bridge Alignment............................................................................................... - 2 -
5.4 Adjusting the Action (string height) ........................................................................................ - 3 -
5.5 Pickup Height (Figure 5.4) ....................................................................................................... - 3 -
5.6 Intonation (Figure 5.6) ........................................................................................................... - 4 -
5.7 …Other Hints........................................................................................................................... - 4 -
Introduction
JS Guitar Intro- 4 -
1Introduction
Thank you for purchasing a BYOGuitar.com guitar kit. This kit includes everything you need to build a
complete custom guitar. In addition to the construction of your guitar, you will need to consider the
finish –natural, solid color and possibly a design that will make your guitar unique. We suggest you do
some research to determine your finish preferences. Procuring the required finishing materials,
especially if they have to be ordered, will allow expedite your guitar project.
We carry a full line of finishing products to give you the beautiful finish you are looking for, whether a
clear natural finish or a bold, colorful finish. We also carry an instructional DVD made by Behlen that will
give you step by step instructions to help you achieve the look you want for your custom guitar.
These instructions assume you are familiar with the anatomy of a guitar. Refer to Figure 1 for many of
the terms used in the assembly of your guitar.
1.1 Material Check List
In preparation for the building of your guitar, all required material should be checked both for type and
quantity. Use the following check list to ensure all piece parts are included. If you customized your
order (ex. different tuners), ensure that these parts are accounted for. Please contact BYO Guitar if
there are any discrepancies.
Fig 1 Major Components in Your JS Guitar Kit
Introduction
JS Guitar Intro- 5 -
JS Guitar Material List
Item
Component
Quantity
Description
1
1 JS Guitar
Body
1 JS Guitar
Neck
Miscellaneous
materials (see
below)
BYO JS Guitar
Kit
2
Volume/Tone
pots
2 Knobs
1 Switch top
Wire: Audio
Controls
Audio Controls
3
11 screws 3/8”
Mounting screws
Audio and Trem
Covers
4
1
2 mounting
inserts/screws
JS Guitar
Bridge/Tremblock
5
Trem Claw
Springs, 3
Screws, 1 ½”,
2
Tremolo parts
TIP: use small
interior packing box to
inventory and organize piece
parts
Introduction
JS Guitar Intro- 6 -
6
Arm
Wammy bar
7
Mounting
plate, 1
Plastic
spacer,1
4 screws, 13/4”
Neck mounting
materials
8
6 Tuning Pegs
6 Washers
6 Nuts
6 screws, 3/8”
Tuning Peg
materials
9
Audio Jack
Output Jack
10
2 Holders
2 plastic
washers
2 screws, 1”
Strap Holder
materials
11
2 Pickups
8 screws, ¾”
Pickups
12
Tremolo claw
cover, 1
Audio cover
Truss rod, 1
Body (back)
Access & truss
rod Covers
13
6 strings
Strings
14
Output Cable
3 Allen
wrenches
Other
Introduction
JS Guitar Intro- 7 -
15
Nut
2 Mounting
screws
Nut
1.2 Additional tools/materials required:
Drill & drill bits
#1 & #2 Phillips
screwdriver
Soldering iron/solder
Masking/painters tape
Finishing/painting material
Sand paper 220 & 320 grit
Guitar strap
Soap or candle
Feeler gauge
ruler
Wood glue
Introduction
JS Guitar Intro- 8 -
The remainder of the assembly instructions is divided into four sections:
Section 2 –Mockup & Fit check: in this section, all components will be checked for proper
alignment and ensure that all holes have been drilled.
Section 3 –Finishing the Body and Neck: after fit check, the components are removed from the
neck & body to allow the selected finish to be applied. This will allow you to customize your guitars’
color(s). As the finishing will likely require several coats with sanding between each coat, ensure that
the finish is completely dry.
Section 4 –Construction: the final assembly is the next step - once the finish has been applied
and completely dried. In this section, all of the components are installed, internal wiring connected and
strings attached –your guitar will ready to go!
Section 5 –Setup: in this section, adjustments are made to your guitar such as the height of the
pickups.
Again, we thank you for your purchase of a BYO Guitar and we look forward to seeing pictures of your
unique guitar! We also look forward to providing you with the guitar for your next project from our
Custom Shop where you can select the wood for the body and neck as well as customizing all of the
other components.
Let us know if your music, school, church or scouting organization would like to undertake a group
project –BYO Guitar can supply multiple kits or custom guitars.
Examples of Our Custom Shop Products
Section 2 –Mockup and Fit Check
JS Guitar Section 2 - 1 -
2Mockup and Fit Check
The following steps will ensure that the base, neck, tuners, pickup, etc. are properly aligned and that all
screw holes have been drilled.
2.1 Check the Neck Holes in the Body for Size (Fig. 2.1)
1. Insert a Neck mounting screw in the Neck pocket holes;
2. Skip to 2.2 if the screw easily passes through the Body.
2.1.1 Enlarge Neck mounting holes in the Body
1. Select a drill bit that is the same size as the mounting screw;
2. Drill a test hole in a scrap piece wood –the mounting screw should
fit through the hole with no resistance;
3. Repeat 1 & 2 until you have the proper drill bit;
4. Drill the four Neck mounting holes in the Body -
ensuring the drill is perpendicular to the Body.
2.2 Check the Mounting Holes in the Neck
1. Check the neck for pre-drilled (4) mounting
holes;
2. Skip to 2.2.2 if the holes are pre-drilled.
2.2.1 Drilling Mounting Holes in the Neck (Fig
2.1)
1. Place the neck in the pocket (…you should be
able to fit the neck in the neck pocket by hand).
a. Make sure the neck is aligned properly with the pickup pocket;
b. Carefully clamp the neck in place –frets damage easily;
c. Using the 3/32 drill bit, place the bit in the hole through the body and tap it a few times
to make a mark on the neck;
d. Remove the neck from the body.
2. Determine the neck mounting hole depth.
a. Place one of the neck mounting screws with mounting plate & plastic spacer (item #7 on
material list) through the body into the neck pocket;
b. Measure the amount of the mounting screw that extends up into the neck pocket, and
mark your drill bit;
c. Double check the depth by holding the marked drill bit to the side of the neck and be
certain the drill won’t go through the fingerboard;
3. Drill the holes in the neck with a 1/8” drill bit. Make sure you don’t drill through the
fingerboard!
TIP…a
piece of masking tape
around the drill bit works
great as a depth
indicator.
Figure 2.1 Neck Mounting Holes
Section 2 –Mockup and Fit Check
JS Guitar Section 2 - 2 -
2.2.2 Mount the Neck on the Body
Temporarily attach the neck. Use caution, the last thing you want to do is snap the screw off in the
hole!
1. Insert the neck into the neck pocket aligning the mounting holes in the neck and body;
2. Using the neck plate & plastic spacer (item #7 on material list), fasten the Neck & Body with 4 - 1
3/8” screws - do not over tighten.
2.3 The Bridge
Mounting the Bridge assembly (item 4 on material list) utilizes
two inserts in the Bridge Pocket (Fig 2.3).
1. Remove the adjustment bolts from the inserts;
2. Using a small block of wood, gently tap the inserts into
the Body - being cautious that the block does not
contact the Body as it might leave small dents that will
require sanding when you finish your guitar. When
finishing the Body (Section 3), be careful not to allow
finish material into the insert holes.
2.4 Fit check & Alignment of the
Pickups (item 11 on material list)
There are two pickups on the JS guitar: the thin
tapered Pickup is mounted closest to the Neck while
the wide tapered is mounted near the Bridge (Figure
2.4-1).
1. From the front of the Body, carefully run the Pickup shielded pickup wires through the tunnels
between the Pickup pockets and the Audio pocket (Fig. 2.4-2), ensuring that the pickup is flush
against the Body and the taper is facing the Neck;
2. Align and center the Neck pickup over the pocket;
3. Mark the 4 holes, remove the Pickup, and drill
starter holes with 1/16 drill bit;
4. Repeat on the Bridge pickup.
The wiring of the pickup and other components will be
covered in Section 4.
Figure 2.3 Body Pockets
TIP…to reduce the chances of the wood splitting, use soap or wax on screw threads
Figure 2.4-1 Pickup Taper
Figure 2.4-2 Body Tunnels
Section 2 –Mockup and Fit Check
JS Guitar Section 2 - 3 -
2.5 Check Tremolo Claw Alignment and Fit Check (item #5 on material list)
Place the Tremolo claw in the back pocket of the
Body (Fig 2.5) ensuring the claw is centered in the
pocket.
1. In order to make the assembly process easier,
pre-tin (solder) the attachment point for the
claw ground wire (raised tab in the center of
the claw);
2. Skip to 2.6 if holes are drilled;
3. Using the claw as a template, mark the hole
positions and pre-drill 2 holes;
4. Start the mounting screws approximately ½”
into the Body –ensure they are centered (Figure 2.5).
2.6 Fit check of the Covers (Fig 2.6.1)
2.6.1 Tremolo cover:
1. Carefully align and center the rectangular cover over
the pocket, ensuring that there is room for the audio
cover directly below (item 12 in material list);
2. Mark the holes and drill starter holes with 1/16 drill
bit.
2.6.2 Audio Cover:
1. Place cover over the round pocket, with the counter
sunk mounting holes facing up (item 12 in material
list);
2. Mark and drill starter holes with 1/16 drill bit.
2.6.3 Truss Rod Adjustment Access Cover
1. Center the cover over the Truss Rod adjustment
pocket (Figure 2.6.3);
2. Mark and drill starter holes with 1/16 drill bit –use
caution as the headstock is relatively thin.
2.7 Check Strap Pins
1. Check for pre-drilled holes for the Strap Pins (item 10
on the material list), reference Figure 1.0.
2. If the holes are pre-drilled, skip to 2.8.
a. Mark the rear Strap Pin hole so that it is centered on the Neck/Bridge and the forward
Strap Pin on the most forward point on the top of the Body (see Figure 1.0).
Figure 2.5 Tremolo claw Alignment
Figure 2.6.1 Back Body Cover Alignment
Figure 2.6.3 Truss Rod Cover
Section 2 –Mockup and Fit Check
JS Guitar Section 2 - 4 -
b. Drill starter holes with a 1/16 drill bit.
2.8 Check Tuner Alignment
Each tuner consists of the tuner, washer, and a threaded
bushing (item #8 on material list).
1. Skip to 2.9 if tuner holes are drilled;
2. Insert tuners, 6 each, into the Neck Headstock.
Ensure that the Tuner shafts are perpendicular to the
Headstock (Fig. 2.8);
3. Check alignment of set screw holes and tuner base;
4. If alignment is incorrect or holes are not drilled, mark
hole locations and drill starter holes with 1/16 “ drill
bit being careful not to drill through the headstock.
2.9 Check Output Jack
1. The Output Jack (item #9 on the material list) is shaped like a barrel and will be pressed in place
during the assembly process;
2. The nut for the Jack will be removed before installation.
2.10 Check Nut
1. Place the Nut (item #15 on the material list) at the end of the Neck, as shown in Figure 2.6.3.
2. Center the Nut on the Neck, mark the mounting hole locations and drill starter holes with 1/16 “
drill bit being careful not to drill through the headstock.
2.11 Mockup and Fit Check complete!
Carefully disassemble the Mockup and move on to the next step: applying the finish to your guitar!
Figure 2.8 Tuner/Nut Alignment
Section 3 - Finishing Your Guitar
JS Guitar Section 3 - 1 -
3Finish
Before starting the finish make sure all holes are drilled for any remaining hardware (pickguard, jack
plate, strap pins etc). This section will cover the application of several finish types, including;
1. Solid color
2. Pigmented translucent, gel stain or alcohol dye
3. Penetrating stain or water based dye
The guitar body was sanded at the factory and coated with one coat of sand and sealer. To get a good
finish, the body should be sanded with a series of sandpaper grits up to #320 grit. Apply a solid color
finish, a pigmented translucent finish (Bursts, toners, Blonde, Butterscotch Blonde etc), a gel based stain
or an alcohol based dye finish over the sanding sealer. If you plan on using a penetrating stain or water
based dye, the sanding sealer must be removed.
How you proceed will depend on the finish you would like on your guitar.
The following paragraphs outline several finishing processes, starting with the sequence for a finish type
(paragraph 3.1) followed by detailed explanation of each sequence step (paragraph 3.2).
Caution: if you remove the nut/string tie down from the headstock in preparation for finishing the neck,
tape/cover the mounting area on the neck as to avoid material build-up that might influence the tuning
of your guitar.
3.1 Finish Application Steps
3.1.1 Solid Color finish:
1. Sand the body and neck
2. Apply grain filler if desired.
3. Apply 2 coats of sand and sealer
4. Sand to 320 grit
5. Apply primer
6. Sand the primer
7. Apply color coats
8. Apply clear top coats
9. Buff finish
3.1.2 Pigmented Translucent, Gel stain or alcohol dye finish:
1. Sand the body and neck
2. Apply grain filler if desired.
3. Apply 2 coats of sand and sealer
4. Sand to 320 grit
5. Apply stain or dye
6. Apply clear top coats
Section 3 - Finishing Your Guitar
JS Guitar Section 3 - 2 -
7. Buff finish
3.1.3 Penetrating Stain or water based dye finish:
1. Sand the body and neck to bare wood
2. Apply grain filler if desired.
3. Apply stain or dye
4. Apply 2 coats of sand and sealer
5. Sand to 320 grit
6. Apply clear top coats
7. Buff finish
3.2 Explanation of Sequence Steps:
3.2.1 Sanding the Body and Neck
1. Wear a NIOSH-approved respirator and ANSI-approved safety glasses when sanding wood!
2. Before starting the finish on the neck mask off the surface of the fingerboard.
3. Use a flexible sanding block with #150 grit aluminum-oxide sanding paper to sand the guitar
body until there is a consistent scratch pattern on the entire surface. Note: DO NOT round over
the neck pocket or the body cavities. When hand sanding, always sand in the same direction as
the wood grain.
4. Re-sand the entire guitar body and neck with #220 grit sanding paper and lightly round over the
outside edges of the body.
5. Wipe the guitar body and neck with a damp cloth to “raise" the wood grain.
6. Wait until the wood is dry and re-sand with #220 grit sandpaper to sand the “raised" grain
smooth.
(Note: On a maple fingerboard you can apply a clear finish to the entire neck and fingerboard. Apply
several coats and remove buildup on the frets between coats. An easy way to remove the finish buildup
on the frets is to take a nail and file a half round slot in the head about the same size as the frets. You
can then use this to easily scrape any finish build up.
If the neck has a Rosewood or Ebony fingerboard, be sure to tape off the fingerboard before applying
the finish. Behlen’s Fingerboard Oil is a great product for your fingerboard.)
3.2.2 Appling Grain Filler
Grain filler will fill in the grain and create flat surface. This is essential if you are trying to get a high gloss
finish. Oil based grain filler is recommended. We recommend using Behlen PORE-O-PAC grain filler. For
Section 3 - Finishing Your Guitar
JS Guitar Section 3 - 3 -
most finishes use natural colored filler. The dyes used in darker fillers may over time find their way
through the color coat.
Apply the filler by wiping across the grain. You can use a course cloth or your fingers to wipe the grain in.
After it has dried about ten to twenty minutes the excess can be removed with a cloth dampened with
mineral sprits. After about an hour repeat the process and let dry overnight. If you have removed most
of the excess with mineral spirits the remaining filler on the field of the wood can be sanded off (use
#220 again) in a few minutes. It is also a good idea at this time to reopen any of the screw holes in the
body. Use a toothpick or small drill held between your fingers to clean out any filler in the holes. The
body is now ready for a sand and sealer coating.
3.2.3 Applying Sanding Sealer
Sand and sealer is used to give the final coat a level base. It is also helpful in filling scratches which are
too deep to sand out. We recommend using Behlen Vinyl Sealer. This comes in aerosol cans and can
easily be sprayed on.
3.2.4 Solid Color Primer
The last step before applying the color coats is to apply a white primer coat. We recommend using Ohio
Valley Nitro Primer. The white background will also let you apply an opaque color coat with less paint.
Spray on two coats. When dry you may notice that the surface feels rough. Sand off the roughness with
#320 dry and respray. Sand again. If the surface now appears smooth and all grain is opaqued you are
ready for the color coat.
3.2.5 Burst and Translucent finishes
Bursts and Translucent finishes can be applied using aerosol cans of lacquer toner. Ohio Valley Nitro
and Behlen have a full line of Nitrocellulose Lacquer Toners to achieve these finishes.
3.2.6 Clear Top coats
Apply several thin coats of the finish, following the manufacturer's instructions. Multiple thin coats
usually produce a better quality finish than one heavy coat. Dry sand the entire body with #400 grit wet
dry sandpaper after at least three coats of finish have been applied. DO NOT sand through the finish, be
careful on the edges. Use a tack cloth to remove sanding residue. Apply more finish, sanding between
coats, until the finish is the desired thickness.
3.2.7 Buff finish
When the final coat has dried at least a week, preferably a month, remove the masking. Wet sand the
finish using #600 grit wet/dry sandpaper with a sanding block, followed with #1000 grit wet/dry
sandpaper. Use a clean, absorbent rag to remove excess water. Let the guitar dry completely, then use
a tack cloth to remove all residue. Buff the finish by hand or with a buffer, starting with a medium polish
and working up to a high gloss polish.
Note: If you use a buffing machine, be careful to avoid going through the finish, especially on the edges.
Section 4 - Assembling Your Guitar
JS Guitar Section 4 - 1 -
4Assembly
After your finish has been applied and thoroughly dried, we can now assemble your guitar. In this
section we will permanently install all of the components and solder the wiring for the pickup/volume
control –refer to Section 2 for additional diagrams if required.
4.1 Installing the tuners
Each tuner consists of the tuner, washer, and a threaded bushing. The tuners are attached to the
headstock with 3/8” wood screws (refer to Section 2.8).
4. Place the six tuners into the holes on the back of the headstock;
5. Slide a washer over the tuner shaft and secure the threaded bushing onto the tuner –do not
tighten yet;
6. Secure the machine heads to the guitar headstock with the supplied screws - tighten the
threaded bushings. Remove the protective film if necessary.
4.2 Install the Nut
1. Place the Nut at the end of the Neck, attach with the supplied screws (2).
4.3 Neck Installation
1. Insert the neck into the neck pocket, aligning the mounting holes in the neck and body;
2. Fasten the Neck & Body with 4 x 1 3/8” screws – do not over tighten.
4.4 Installing the Strap Pins
Secure each strap pins (2) in the pre-drilled holes with the supplied screws (2ea, 1”).
4.5 Installing the Floyd Rose Tremolo (items 4 & 5 on material list)
Unlike hard mounted bridges, the Floyd Rose style utilizes a
floating bridge base that allows the tremolo to pivot
forward and backward. The floating bridge is balanced
(positioned) between the tension of the strings and the
tension of the springs in the back pocket in the body of your
guitar. This type of system requires several iterations of the
string & spring tension adjustment to optimize your style of
playing.
TIP… use a blanket or large towel on your work area to protect your guitars’ finish
Figure 4.5-1 Tremolo Claw Installation
Section 4 - Assembling Your Guitar
JS Guitar Section 4 - 2 -
1. Install the Trem claw in the front of the bottom Pocket (Fig 4.5-1), ensuring it is centered in the
Pocket, so that about ½ of the screw threads are exposed. This allows you to adjust the tension
of the springs;
2. Insert the Bridge mount adjustment screws into the
inserts –final height adjustment will be made when
the strings are installed;
3. Prior to installing the trem block, set the Fine
Adjustment screws to mid-range (Fig. 4.5-2) and
loosen the string locking bolts so they can be hand
tightened. Should the saddle blocks (small black
inserts behind the string saddle) fall out, ensure
that the indention faces the locking bolt when you
replace them;
4. Insert the trem block in the front of the Body and
attach the springs using pliers to stretch the springs
into position. Use the center and each end tab on
the claw to attach the 3 springs (Fig 4.5-3). [
Caution: if you lose grip of a spring it can fly and
cause injury as well as damage to the paint on the
body] Tighten the screws on the spring claw so
there is a little play in the block. The block still
needs to be able to move if you plan on using a
whammy bar.
4.6 Install the Pickup
Install the Pickups (item #11 on material list) as follows:
1. Run the shielded Pickup wires through the tunnels (Fig. 2.4-2) to the Audio pocket –ensuring
the pickup tapers are correct (Figure 2.4-1);
2. Carefully secure the to the Body with supplied ¾” screws;
4.7 Prep the for the Output Jack, Volume control & wiring
In this section, you will identify the components that need to be soldered, trim the wiring and pre-wire
components to be installed later. As soldering to mounted components can be difficult, pre-wiring will
save you time.
4.7.1 Wire color coding/prep
Several suppliers are used, possibly resulting in different wire colors. Identification of colors and cross
referencing their function to the colors in the instructions (Figure 4.7.1-1) will assist in the assembly.
Using Table 4.7.1, cross reference supplied wire color codes with colors used in these instructions:
Figure 4.5-3 Tremolo Claw Installation
Figure 4.5-2 Bridge Adjustments
Installation
Section 4 - Assembling Your Guitar
JS Guitar Section 4 - 3 -
Table 4.7.1 Wire Color Code Cross Reference
Instruction Color Code
(Figure 4.7.2-1)
Your color code
Function
Black & Red Black
Red
…………………………….
…………………………….
Audio output Ground
Signal
Blue
…………………………….
Neck Pickup Signal (typically WHITE w/shield)
Blue
…………………………….
Bridge Pickup Signal (typically RED w/shield)
Black Black …………………………….
Tremolo & Volume pot ground
1. Strip the insulation back about 3/8” for the Trem ground wire;
2. Strip the insulation back approximately ½” for the Neck/Bridge Pickups and Audio out wires;
3. Tin the wires.
4.7.2 Soldering the Components
Pre-wiring several of the components will ease the final assembly and reduce the opportunity of
scratching your guitar (refer to the color translation table as required).
1. Secure the Volume control, the Tone control and wiring harness (item 2 on the material list) in
the Audio pocket in the Body for soldering;
a. Secure Volume & Tone potentiometers to Body –use caution as to not scratch the
finish. Install the knobs;
Figure 4.7.1-1 JS Wiring Diagram
Section 4 - Assembling Your Guitar
JS Guitar Section 4 - 4 -
b. Run the Bridge ground wire through the tunnel from the Audio pocket to the Trem
Pocket;
c. Run the audio output wires (red & black) through the Jack tunnel.
2. Solder the Bridge ground wire to the raised tab on the Trem claw;
3. Remove the nut from the Output Jack, then solder the red &
black wires that have been run through the Jack tunnel to the
Jack (Figure 4.7.2-1). Insert the Jack into the Body while pulling
the wires back into the Audio Pocket. Gently tap the jack until it
is tight against the Body;
4. Solder the Neck Pickup wire to pins 6&7 of the Selector switch
(reference Figure 4.7.2-2);
5. Solder the Bridge Pickup to wire to pins 1&2 of the Selector
switch;
6. Solder the shields from the Neck & Bridge Pickups to ground on
the switch and/or the potentiometer case;
7. Secure the Selector switch to the Body with supplied screws.
Install the switch cap;
8. Ensure the Audio controls/switch are tightened;
9. Check the wiring to ensure there are no broken wires or solder joints, then install the Audio
cover.
4.8 Install the Strings
Like most projects, there often
several tricks that will make the
assembly easier and your guitar
better. Properly stringing your guitar
is just one of those tricks. Please
review the following videos:
Figure 4.7.2-1 Output Jack Wiring
Tip…
try these links if you are new to soldering:
https://www.youtube.com/watch?v=KjI4r82N3uQ , https://www.youtube.com/watch?v=NUVX_RTS-
Z8
Figure 4.7.2-2 Body Wiring Tunnels
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